CN112528502B - Control method, control system and related device for production workshop - Google Patents
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Abstract
The application relates to the field of production workshop management and discloses a control method, a control system and a related device of a production workshop. The method comprises the following steps: acquiring production data of a production workshop; simulating on the virtual model based on the production data, and obtaining a simulation result; wherein, the virtual model is obtained according to the equipment and environment mapping of the production workshop; and generating a control instruction according to the simulation result so as to control equipment or environment of the production workshop. By the mode, the management level of a production workshop is improved, the production efficiency is improved, and the production cost is reduced.
Description
Technical Field
The application relates to the field of production workshop management, in particular to a control method, a control system and a related device of a production workshop.
Background
The injection molding industry belongs to the typical discrete flow industry, and has the characteristics and complexity that: the production mode of multiple varieties, small batch and even single piece makes new products developed frequently; the manufacturing process is complex, and the relevance of each manufacturing process in production is strong; the probability of plan change in the production process is very large, the production environment is complex and changeable, the problems of temporary bill insertion, material shortage and the like in the production process occur, and the production period of the product is greatly influenced by the production period of key equipment. The implementation of the injection molding process often requires production equipment such as an injection molding machine, a mold, a hot runner temperature control device, a mold temperature machine, a feeding device, a manipulator and the like. Meanwhile, there is often a large amount of data to be processed in the injection molding process, such as product data, stock data, material quota data, production plan data, processing information, process information, man-hour information, cost accounting information, and the like.
In the production management process of an injection molding workshop, because the production equipment relates to multiple types, brands and models, equipment interfaces are not uniform and are difficult to interconnect and communicate, the production condition of the injection molding workshop cannot be mastered in real time, and the real-time interaction, dynamic optimization and automatic adjustment of the injection molding production process are difficult to realize.
The related injection molding process management and control system can realize the functions of production planning scheduling, process statistics and the like of injection molding orders, but is difficult to monitor the production process in real time, and cannot perform dynamic interaction and optimization adjustment on the injection molding production process, so that the problems of low production efficiency, high production cost and the like are caused.
Disclosure of Invention
The application mainly solves the technical problems of providing a control method, a control system and a related device for a production workshop, which can improve the management level and the production efficiency of the production workshop and reduce the production cost.
The technical scheme adopted by the application is to provide a control method for a production workshop, which comprises the following steps: acquiring production data of a production workshop; simulating on the virtual model based on the production data, and obtaining a simulation result; wherein, the virtual model is obtained according to the equipment and environment mapping of the production workshop; and generating a control instruction according to the simulation result so as to control equipment or environment of the production workshop.
The simulation is performed on the virtual model based on the production data, and a simulation result is obtained, including: acquiring production element data and production tasks; inputting the production task and the production element data into a virtual model for simulation so as to configure the production task by using the production element data to obtain configuration data; generating a control instruction according to the simulation result to control equipment or environment of the production workshop, including: and generating a control instruction according to the configuration data so as to allocate the production elements of the production workshop.
The method for simulating the production task and the production element data input to the virtual model to configure the production task by using the production element data to obtain configuration data comprises the following steps: acquiring historical production element data; inputting the production task and the historical production element data into a virtual model for simulation so as to perform initial configuration on the production task by utilizing the historical production element data and obtain first configuration data; acquiring current production element data; and inputting the current production element data into the virtual model for simulation so as to correct the first configuration data by utilizing the current production element data to obtain second configuration data.
The simulation is performed on the virtual model based on the production data, and a simulation result is obtained, including: acquiring historical simulation data and an estimated production plan; inputting the historical simulation data, the expected production plan and the production data into a virtual model for simulation, and adjusting the production plan by utilizing the historical simulation data and the production data to obtain a target production plan; generating a control instruction according to the simulation result to control equipment or environment of the production workshop, including: and generating control instructions according to the target production plan so as to schedule the production plan for the equipment of the production plant.
The simulation is performed on the virtual model based on the production data, and a simulation result is obtained, including: when the abnormal data is obtained, the abnormal data and the production data are input into a virtual model for simulation, so that a simulation result is obtained; generating a control instruction according to the simulation result to control equipment or environment of the production workshop, including: and generating a scheduling instruction based on the simulation result, and scheduling the equipment of the production workshop according to the scheduling instruction.
The method for scheduling the equipment in the production workshop according to the scheduling instruction comprises the following steps of: acquiring historical production data; generating a scheduling instruction according to the historical production data, the simulation result and the production data, and scheduling equipment of a production workshop according to the scheduling instruction.
The simulation is performed on the virtual model based on the production data, and a simulation result is obtained, including: inputting the production data into a virtual model for simulation to obtain a fault prediction result and/or a productivity prediction result of a production workshop; generating a control instruction according to the simulation result to control equipment or environment of the production workshop, including: and generating a control instruction according to the failure prediction result and/or the productivity prediction result so as to monitor the failure or the productivity of the equipment in the production workshop.
Another technical scheme adopted by the application is to provide a management terminal of a production workshop, wherein the management terminal comprises a processor and a memory coupled with the processor; the memory is used for storing program data, and the processor is used for executing the program data so as to realize the method provided by the technical scheme.
Another aspect of the present application is to provide a computer readable storage medium storing program data, which when executed by a processor, is configured to implement the method provided in the above aspect.
The application adopts another technical scheme that a control system of a production workshop is provided, and the control system comprises: the data acquisition device is arranged in the production workshop and used for acquiring production data of the production workshop; the management terminal is connected with the data acquisition device and is provided by the technical scheme.
Wherein, management and control system still includes: and the network equipment is connected with the data acquisition device and is used for acquiring production data, transmitting and storing.
The data acquisition device comprises at least one of an RFID device, a mold sensor and an equipment controller; the RFID device is connected with the network equipment, is arranged at a preset station of the production workshop and is used for collecting personnel data of the production workshop; the die sensor is connected with the network equipment and is used for collecting the operation data of the die; the equipment controller is connected with the network equipment and is arranged on equipment of the production workshop and used for controlling the equipment and sending operation data of the equipment to the network equipment.
The virtual model is formed by mapping personnel data, position information of a preset station, raw materials, die accessories, space positions of cutters, stock states, design data of the dies, three-dimensional dimensions of equipment and environments of production workshops.
The beneficial effects of the application are as follows: in contrast to the prior art, the method for controlling a production plant according to the application comprises: acquiring production data of a production workshop; simulating on the virtual model based on the production data, and obtaining a simulation result; wherein, the virtual model is obtained according to the equipment and environment mapping of the production workshop; and generating a control instruction according to the simulation result so as to control equipment or environment of the production workshop. By the mode, the virtual model utilizes the production data of the production workshop to simulate the production of the production workshop, and achieves interactive mapping and iterative optimization of the production workshop and the virtual model, so that real-time production control and process dynamic optimization adjustment are carried out on the production workshop, the production process is optimized, the production efficiency is improved, and the production cost is reduced.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for the description of the embodiments will be briefly described below, and it is apparent that the drawings in the following description are only some embodiments of the present application, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art. Wherein:
FIG. 1 is a schematic flow chart of an embodiment of a control method for a production plant according to the present application;
FIG. 2 is a schematic structural view of an embodiment of a management terminal of a production plant according to the present application;
FIG. 3 is a schematic flow chart of another embodiment of a control method for a production plant according to the present application;
FIG. 4 is a schematic flow chart of step 32 in FIG. 3 according to the present application;
FIG. 5 is a schematic flow chart diagram of another embodiment of a control method for a production plant according to the present application;
FIG. 6 is a schematic flow chart diagram of another embodiment of a control method for a production plant according to the present application;
FIG. 7 is a schematic view of another embodiment of a management terminal of a production plant according to the present application;
FIG. 8 is a schematic diagram illustrating the structure of an embodiment of a computer-readable storage medium provided by the present application;
FIG. 9 is a schematic diagram of a control system for a manufacturing plant according to an embodiment of the present application;
fig. 10 is a schematic structural diagram of another embodiment of a control system of a production plant according to the present application.
Detailed Description
The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application. It is to be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the application. It should be further noted that, for convenience of description, only some, but not all of the structures related to the present application are shown in the drawings. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
Reference herein to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the application. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Those of skill in the art will explicitly and implicitly appreciate that the embodiments described herein may be combined with other embodiments.
Referring to fig. 1, fig. 1 is a schematic flow chart of an embodiment of a control method for a production plant according to the present application. The method comprises the following steps:
Step 11: and acquiring production data of a production workshop.
In some embodiments, the production data of different manufacturing plants may also be different, such as a stamping plant, which may include multiple stamping devices, such as a stamping press, a robot, a test terminal, etc. The production data may be the brand, specification, model number, working time, stamping speed, precision, and status information of the stamping device.
In some embodiments, production data may be collected by a data collection device. For example, the data acquisition device is connected with equipment of a production workshop and is used for acquiring production data of the equipment. In an application scenario, the data acquisition device comprises a data acquisition controller and at least one acquisition terminal. The acquisition terminal is connected with the production equipment and is used for acquiring production data of the production equipment. The data acquisition controller is connected with the acquisition terminal and the network equipment and is used for transmitting the production data acquired by the acquisition terminal to the network equipment. The production data of the production equipment can be acquired by the acquisition terminal in real time or can be acquired at fixed time, such as once every 1 minute, once every 5 minutes, once every 10 minutes, and the like. Step 11 may be in particular the acquisition of production data of a production plant from a network device.
It will be appreciated that the data acquisition controller may be connected to the network device wirelessly or by a wired connection. For example, the data acquisition controller and the network device can be connected through a wireless local area network, or a network cable port is arranged on the data acquisition controller and connected with the network device through a network cable.
In some embodiments, the data acquisition device is connected with the management terminal, and the production data acquired by the data acquisition device is directly transmitted to the management terminal.
In some embodiments, production data for a production plant may be acquired in real-time.
Step 12: simulating on the virtual model based on the production data, and obtaining a simulation result; wherein the virtual model is obtained according to the equipment and environment mapping of the production workshop.
In some embodiments, the virtual model is derived from a plant and environment map of the production plant. The environmental number may include, among other things, the temperature, humidity, noise, personnel, etc. of the production plant. For example, the three-dimensional model is mapped by using personnel data of a production workshop, position information of a preset station, raw materials, die accessories, space positions of cutters, stock states, design data of the dies, three-dimensional dimensions of equipment and environments of the production workshop. The three-dimensional size of the equipment can establish corresponding virtual equipment in a virtual model, the design data of the mould can establish corresponding virtual moulds in the virtual model, the personnel data and the position information of the preset stations can establish corresponding virtual personnel and virtual stations in the virtual model, and the space positions and the stock states of the raw materials, the mould accessories and the cutters can establish corresponding virtual raw materials, the virtual mould accessories and the space positions and the virtual stock states of the virtual cutters in the virtual model.
In some embodiments, when a new order requirement is acquired, production data is acquired, and the production data is input into a virtual model for simulation to determine production equipment suitable for production, and control instructions are generated based on the production equipment.
In some embodiments, the production equipment is maintained and arranged according to the set production time or production batch and the production control instruction is generated to carry out maintenance reminding according to the production data.
In some embodiments, the production data is input to the virtual model for simulation, and the usage requirements of the material can be obtained through simulation, and then the control instruction is generated according to the usage requirements.
Step 13: and generating a control instruction according to the simulation result so as to control equipment or environment of the production workshop.
In some embodiments, the simulation results are configuration information of the production elements, and then control instructions can be generated according to the configuration information to control equipment or environment of the production plant. For example, the configuration information may be a setting of a temperature of a production plant, a setting of materials, a configuration of a number of people, and a setting of a process flow.
In some embodiments, the simulation result is a production plan, and control instructions are generated according to the target production plan to schedule production plans for the equipment of the production plant.
In some embodiments, the control instructions may be suggested reminders that are presented via a display interface. For example, the monitored and managed data are sent to the mobile terminal and the computer end through the network, so that people with different identities in the production workshop can check the data.
In an application scenario, the method is applied to a management terminal. Referring to fig. 2, fig. 2 is a schematic structural diagram of an embodiment of a management terminal of a production plant according to the present application. The management terminal 20 includes a virtual model module 21, a twin data module 22, and an interactive system module 23. Wherein the virtual model module 21 is a plant and environment map of the production plant. The twinning data module 22 includes the collected production data of the production plant and the construction data of the virtual model module 21. The interactive system module 23 performs simulation in the virtual model module 21 by analyzing and processing the industrial process data of the twin data module 22; and the simulation result, the real-time production data, the historical production data and other twin data are evaluated and predicted, and a real-time monitoring instruction is generated so as to perform feedback control on equipment and the like of the production workshop, thereby realizing interactive mapping of the virtual model module 21 and the production workshop.
In this embodiment, production data of a production shop is acquired; simulating on the virtual model based on the production data, and obtaining a simulation result; wherein, the virtual model is obtained according to the equipment and environment mapping of the production workshop; and generating a control instruction according to the simulation result so as to control equipment or environment of the production workshop. The production of the production workshop is simulated by utilizing the production data of the production workshop through the virtual model, and the interactive mapping and iterative optimization of the production workshop and the virtual model are realized, so that the real-time production control and the process dynamic optimization adjustment are carried out on the production workshop, the production process is optimized, the production efficiency is improved, and the production cost is reduced.
Referring to fig. 3, fig. 3 is a flow chart of another embodiment of a control method for a production plant according to the present application. The method comprises the following steps:
step 31: production element data and production tasks are acquired.
In some examples, the production task may be a production order. The production element data may be the number of personnel in a production plant, production equipment, materials, process flows, environmental data, etc.
Step 32: and inputting the production task and the production element data into a virtual model for simulation so as to configure the production task by using the production element data and obtain configuration data.
In some embodiments, taking the production shop as an injection molding production shop as an example, the following description is made with reference to fig. 2: when a production task is acquired, the interactive system module 23 acquires historical production element data from the twin data module 22, and simulates the current production task and the historical production element data in the virtual model module 21 to obtain initial configuration data; meanwhile, real-time data of production element data such as personnel, molds, injection molding machines and materials in a production workshop are acquired, states of the production element data are analyzed, evaluated and predicted, an initial configuration scheme is optimized, an order regulation and control instruction is generated, and the production element data in the production workshop are guided to be allocated.
Specifically, referring to fig. 4, step 32 may be the following procedure:
Step 321: historical production element data is acquired.
In some embodiments, the historical production element data corresponds to the plant historical production task, and production element configuration data for the historical production task can be embodied.
Step 322: and inputting the production task and the historical production element data into a virtual model for simulation so as to perform initial configuration on the production task by utilizing the historical production element data and obtain first configuration data.
Step 323: current production element data is obtained.
Step 324: and inputting the current production element data into the virtual model for simulation so as to correct the first configuration data by utilizing the current production element data to obtain second configuration data.
It will be appreciated that the current production element data is more reflective of the actual situation of the production plant and therefore the first configuration data needs to be modified in connection with the current production element data.
Step 33: and generating a control instruction according to the configuration data so as to allocate the production elements of the production workshop.
In some embodiments, the steps are performed in real time, and during the production process of the production plant, the optimization is performed in real time, so that different time periods of the production plant can be correspondingly optimized, and the production plant can obtain the optimal configuration of the production elements.
In this embodiment, the virtual model simulates production in the production plant by using the production element data and the production task to obtain the optimal configuration information of the production element data, and the production element data in the production plant is allocated according to the configuration information, so that real-time production control and process dynamic optimization adjustment are performed in the production plant, thereby optimizing the production process, improving the production efficiency and reducing the production cost.
Referring to fig. 5, fig. 5 is a flow chart of another embodiment of a control method for a production plant according to the present application. The method comprises the following steps:
step 51: historical simulation data and a projected production plan are obtained.
In the above embodiment, when the production task is acquired and the configuration information of the production element is obtained, the corresponding expected production plan is produced.
Step 52: and inputting the historical simulation data, the expected production plan and the production data into a virtual model for simulation, and adjusting the production plan by utilizing the historical simulation data and the production data to obtain the target production plan.
Step 53: and generating control instructions according to the target production plan so as to schedule the production plan for the equipment of the production plant.
The description is given in connection with fig. 2: when the virtual model module 21 receives the estimated production plan, historical simulation data and real-time production data are acquired in the twin data module 22, the estimated production plan is subjected to simulation optimization based on logic, rule models and algorithms with optimal injection molding production time and lowest cost, and simulation results are fed back to the twin data module 22. The interactive system module 23 performs optimization simulation according to the feedback simulation result, transmits the simulation result to the virtual model module 21, and performs iterative optimization until an optimal scheme of production plan scheduling and a production running instruction based on the scheme are obtained, and drives and controls equipment of a production workshop to schedule production plans.
In this embodiment, the virtual model simulates production in the production plant by using the historical simulation data and the predicted production plan to obtain an optimal production plan, and schedules production plans for equipment in the production plant according to the optimal production plan, so as to perform real-time production control and process dynamic optimization adjustment on the production plant, thereby optimizing the production process, improving the production efficiency and reducing the production cost.
Referring to fig. 6, fig. 6 is a flow chart of another embodiment of a control method for a production plant according to the present application. The method comprises the following steps:
step 61: and acquiring production data of a production workshop.
Step 62: when the abnormal data is obtained, the abnormal data and the production data are input into the virtual model for simulation, so that a simulation result is obtained.
Step 63: and generating a scheduling instruction based on the simulation result, and scheduling the equipment of the production workshop according to the scheduling instruction.
In one application scenario, the production plant is an injection molding plant comprising 10 injection molding machines. Of which 8 are in normal operation and 2 are in idle state. When two injection molding machines which normally work are abnormal, simulation is carried out on the virtual model according to abnormal data and production data so as to obtain a simulation result. Simulation results show that the abnormal two injection molding machines cannot complete tasks within a specified time, and it is recommended to use an idle injection molding machine instead of working. And carrying out production scheduling according to the simulation result to enable the idle injection molding machine to work so as to complete production tasks, wherein the scheduling instruction comprises scheduling of materials and personnel.
In the embodiment, the optimal production scheduling during abnormality is realized by using the virtual model, and the problem of production efficiency reduction caused by abnormality is solved, so that real-time production control and process dynamic optimization adjustment are performed on a production workshop, thereby optimizing the production process, improving the production efficiency and reducing the production cost.
In other embodiments, the production data is input into a virtual model for simulation to obtain a fault prediction result of the production plant; and generating a control instruction according to the fault prediction result so as to monitor the faults of the equipment in the production workshop. The description is given in connection with fig. 2: in the production process, production data are collected in real time and transmitted to the twin data module 22 in real time, the virtual model module 21 performs fault prediction, diagnosis simulation, capacity prediction and the like based on the real-time data in the production process, the interactive system module 23 evaluates and predicts the twin data according to simulation results, the real-time production data, historical production data and the like, and generates a real-time monitoring instruction to drive a physical space to realize functions of equipment maintenance, capacity prediction evaluation and the like until the production of an order is completed.
In other embodiments, the production data is input into a virtual model for simulation to obtain a production capacity prediction result of the production plant; and generating a control instruction according to the productivity prediction result so as to monitor the productivity of the equipment in the production workshop. For example, the production data is input into the virtual model for simulation, so that the production capacity prediction result of the production plant is 1000/day. And generating a control instruction based on the productivity prediction result, and monitoring the productivity of the equipment in the production workshop every day to see whether the achievement and the productivity prediction result can be achieved. And the simulation can be carried out in the virtual model according to the actual productivity, and the optimization of the productivity prediction result is carried out again so as to obtain the optimal productivity prediction result.
In this embodiment, the virtual model is used to implement productivity prediction and use historical simulation data and a predicted production plan, so as to simulate production in a production shop, to obtain an optimal production plan, and to schedule production plans for equipment in the production shop according to the optimal production plan, so as to perform real-time production control and process dynamic optimization adjustment on the production shop, thereby optimizing the production process, improving the production efficiency, and reducing the production cost.
Referring to fig. 7, fig. 7 is a schematic structural diagram of another embodiment of a management terminal of a production plant according to the present application. The management terminal 70 includes a processor 71 and a memory 72 coupled to the processor 71; the memory 72 is used for storing program data, and the processor 71 is used for executing the program data to implement the following method:
Acquiring production data of a production workshop; simulating on the virtual model based on the production data, and obtaining a simulation result; wherein, the virtual model is obtained according to the equipment and environment mapping of the production workshop; and generating a control instruction according to the simulation result so as to control equipment or environment of the production workshop.
It will be appreciated that the processor 71 in this embodiment may also implement any of the methods in the above embodiments, and will not be described herein.
The management terminal 70 of the embodiment simulates the production of the production workshop by using the production data of the production workshop through the implementation of the method, and realizes the interactive mapping and iterative optimization of the production workshop and the virtual model, so as to perform real-time production control and process dynamic optimization adjustment on the production workshop, thereby optimizing the production process, improving the production efficiency and reducing the production cost.
Referring to fig. 8, fig. 8 is a schematic structural diagram of an embodiment of a computer readable storage medium according to the present application. The computer readable storage medium 80 is for storing program data 81, which program data 81, when executed by a processor, is for carrying out the method of:
Acquiring production data of a production workshop; simulating on the virtual model based on the production data, and obtaining a simulation result; wherein, the virtual model is obtained according to the equipment and environment mapping of the production workshop; and generating a control instruction according to the simulation result so as to control equipment or environment of the production workshop.
It will be appreciated that the computer readable storage medium 80 in this embodiment may also implement any of the methods of the above embodiments, and will not be described here again.
When the computer readable storage medium 80 of the embodiment is applied to the above management terminal, the virtual model utilizes the production data of the production workshop to simulate the production of the production workshop, so as to realize the interactive mapping and iterative optimization of the production workshop and the virtual model, thereby carrying out real-time production control and process dynamic optimization adjustment on the production workshop, optimizing the production process, improving the production efficiency and reducing the production cost.
Referring to fig. 9, fig. 9 is a schematic structural diagram of an embodiment of a control system of a production plant according to the present application. The management and control system 90 comprises a data acquisition device 91 and a management terminal 92. The data acquisition device 91 is arranged in the production workshop and is used for acquiring production data of the production workshop. The management terminal 92 is connected to the data acquisition device 91, and the management terminal 92 is the management terminal in the above-described embodiment.
Further, referring to fig. 10, the management and control system 90 includes, in addition to the data acquisition device 91 and the management terminal 92, a network device 93 connected to the data acquisition device 91 for acquiring production data and transmitting and storing the data.
Specifically, the network device 93 may be communicatively connected to the data acquisition device 91 and the management terminal 92 by using a fieldbus or an industrial ethernet, etc. The network devices 93 may include network devices such as routers, switches, edge computing servers, plant database servers, cloud servers, and the like.
The data acquisition device 91 includes at least one of an RFID device, a mold sensor, and an equipment controller. The RFID device is connected to the network device 93, and is disposed at a preset station of the production shop, and is used for collecting personnel data of the production shop. The mold sensor is connected to a network device 93 for collecting operational data of the mold. The device controller is connected to the network device 93, and is disposed on a device in the production plant, and is configured to control the device and send operation data of the device to the network device 93.
The virtual model in the management terminal 92 is mapped by using personnel data, position information of a preset station, raw materials, die accessories, space positions of a cutter, stock state, design data of the die, three-dimensional size of equipment and environment of a production workshop.
In some embodiments, the production workshop is an injection workshop, and data such as personnel, materials, equipment and the like are involved in the production process of the injection workshop, wherein a large number of different types, brands and models of equipment exist in the production workshop, interface protocols and the like are different, and in order to realize heterogeneous equipment data acquisition, a unified standardized communication frame and protocol need to be established. Because OPC UA (OLE for Process Control Unified Architecture, OLE unified architecture for process control) supports complex data built-in, cross-platform operations, provides unified address space and services, and the above devices mostly support OPC UA protocol, a communication architecture based on injection molding production process of OPC UA protocol is adopted. The data of the injection molding production process in the production workshop is acquired through RFID, a data acquisition device, a mold sensor, an injection molding machine controller and the like, and is transmitted to a data server in real time through a field bus or an industrial Ethernet based on OPC UA protocol.
In some embodiments, the virtual model module in the management terminal 92 is capable of accurately mapping the equipment and environment of the production plant described above with high fidelity, multiple time scales, multiple space dimensions. The digital modeling can be performed by using three-dimensional CAD (Computer AIDED DESIGN ) systems such as units 3d, 3Dmax, maya and the like to obtain a virtual model. Specifically, the virtual model module comprises a personnel virtual model, a material virtual model, a mould virtual model, an equipment virtual model and an environment virtual model.
The personnel virtual model is mainly embodied in personnel actions and space positions in a production workshop, a human body structure is mapped through the three-dimensional structure model, identity and position positioning is carried out by adopting RFID or fingerprint image recognition, and management and control of personnel positions and identities are realized in the virtual model module.
The material virtual model mainly comprises the space positions and stock states of plastic raw materials, mould accessories, cutters and the like, and data information is acquired through a stock material management system or an ERP (ENTERPRISE RESOURCE PLANNING ) system.
The mold virtual model is mainly CAD/CAM (Computer Aided Manufacturing )/CAE (Computer AIDED ENGINEERING, computer aided engineering)/CAPP (Computer Aided Process Planning, computer aided process design) data of the mold, and can be obtained directly through a PDM (Product DATA MANAGEMENT) system or a CAX system. Wherein CAX is a comprehensive term for various technologies such as CAD, CAM, CAE, CAPP, because all abbreviations begin with CA and X represents all. In fact, the CAX integrates diversified computer-aided technologies to perform work in a compound and coordinated manner, besides the work of a design department in product design, other departments can also intervene in advance without waiting for the completion of the previous operation before starting the next operation, so that development time is shortened; meanwhile, various factors of the life cycle of the product can be well considered in early stage of product design, errors and errors in design can be found in advance, correction can be performed in time, and various comparable design schemes can be continuously proposed according to market demands in the design process, so that optimal design results and benefits are obtained.
The equipment virtual model is the most critical and complex, and particularly comprises an injection molding machine, an industrial robot, a mold temperature machine, a loading and unloading device and the like. In order to complete the real mapping of the twin model to the physical entities, the model must ensure that the three-dimensional size and the behavior are consistent with the physical entities of the devices, and the virtual-real communication control interface needs to be established to acquire data in real time, and the related virtual service needs to be defined to complete the action behavior of the devices.
The virtual model of the environment is mainly a map of the environment of the production plant, such as temperature, humidity, noise, etc.
In an application scenario, an injection molding workshop is taken as an example for explanation, and data acquisition of an industrial production process of the injection molding workshop is performed. The method comprises the steps of acquiring data of key generating elements such as equipment, personnel, materials, environment and the like of an injection workshop in real time through an RFID, a data acquisition device, a mold sensor and an injection molding machine controller, transmitting the data to a server in real time through a field bus or an industrial Ethernet based on an OPC UA protocol, and forming a twin database.
And establishing a virtual model of the injection molding workshop. By analyzing the physical entity elements of the injection molding workshop, a virtual model of production elements such as an injection molding machine, a mold, personnel, materials, environment and the like can be established by adopting three-dimensional CAD systems such as units 3d, 3Dmax, maya and the like.
The twin database is provided with a data interface, and the virtual model of the injection workshop can acquire real-time industrial data of the injection workshop and display real-time states of injection workshop equipment and environment in real time.
In a virtual model of an injection molding workshop, carrying out simulation optimization of a production process, feeding back a simulation optimization result to a twin database, and generating an interaction instruction by an interaction system according to the optimization result in the twin database for dynamic control optimization of the physical space of the injection molding workshop, so as to realize interaction mapping of the physical space of the injection molding workshop and the virtual model.
The method and the device adopt innovative fusion application based on digital twin and injection molding production processes, firstly, a virtual model corresponding to an injection molding workshop is established, twin data is established through real-time acquisition of production data of the injection molding workshop, and interactive mapping and iterative optimization of physical space and model space are realized by combining analysis processing of industrial data, so that real-time production control and process dynamic optimization adjustment of the injection molding workshop are realized, the production process is optimized, the production efficiency is improved, and the production cost is reduced.
In the several embodiments provided in the present application, it should be understood that the disclosed method and apparatus may be implemented in other manners. For example, the above-described device embodiments are merely illustrative, e.g., the division of the above modules or units is merely a logical functional division, and there may be additional divisions when actually implemented, e.g., multiple units or components may be combined or integrated into another system, or some features may be omitted, or not performed.
The units described above as separate components may or may not be physically separate, and components shown as units may or may not be physical units, may be located in one place, or may be distributed over a plurality of network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the embodiment.
In addition, each functional unit in each embodiment of the present application may be integrated in one processing unit, each unit may exist alone physically, or two or more units may be integrated in one unit. The integrated units may be implemented in hardware or in software functional units.
The integrated units of the other embodiments described above may be stored in a computer readable storage medium if implemented in the form of software functional units and sold or used as stand alone products. Based on such understanding, the technical solution of the present application may be embodied in essence or a part contributing to the prior art or all or part of the technical solution in the form of a software product stored in a storage medium, including several instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) or a processor (processor) to execute all or part of the steps of the method according to the embodiments of the present application. And the aforementioned storage medium includes: a usb disk, a removable hard disk, a Read-Only Memory (ROM), a random access Memory (RAM, random Access Memory), a magnetic disk, or an optical disk, or other various media capable of storing program codes.
The foregoing description is only of embodiments of the present application, and is not intended to limit the scope of the application, and all equivalent structures or equivalent processes using the descriptions and the drawings of the present application or directly or indirectly applied to other related technical fields are included in the scope of the present application.
Claims (9)
1. A method for controlling a production plant, wherein the production plant is an injection molding plant, the method comprising:
Acquiring production data of a production workshop;
Simulating on the virtual model based on the production data, and obtaining a simulation result; wherein the virtual model is obtained according to equipment and environment mapping of the production workshop; the virtual model is formed by mapping personnel data, position information of a preset station, raw materials, die accessories, space positions of cutters, stock states, design data of the dies, three-dimensional dimensions of equipment and environments of production workshops;
Generating a control instruction according to the simulation result to control equipment or environment of the production workshop;
The simulation is performed on a virtual model based on the production data, and a simulation result is obtained, including:
Acquiring production element data and production tasks, and acquiring historical simulation data and an estimated production plan; the production element data comprise personnel number, production equipment, materials, process flows and environment data of a production workshop;
Inputting the production task and the production element data into the virtual model for simulation so as to configure the production task by utilizing the production element data to obtain configuration data;
Inputting the historical simulation data, the expected production plan and the production data into the virtual model for simulation so as to adjust the production plan by utilizing the historical simulation data and the production data to obtain a target production plan;
When the abnormal data is obtained, inputting the abnormal data and the production data into the virtual model for simulation so as to obtain a simulation result;
The generating a control instruction according to the simulation result to control equipment or environment of the production workshop comprises the following steps:
Generating a control instruction according to the configuration data so as to allocate the production elements of the production workshop;
Generating a control instruction according to the target production plan so as to schedule the production plan for equipment of the production workshop;
And generating a scheduling instruction based on the simulation result, and scheduling the equipment of the production workshop according to the scheduling instruction.
2. The method of claim 1, wherein the step of determining the position of the substrate comprises,
Inputting the production task and the production element data into the virtual model for simulation so as to configure the production task by using the production element data to obtain configuration data, wherein the method comprises the following steps:
Acquiring historical production element data;
inputting the production task and the historical production element data into the virtual model for simulation so as to perform initial configuration on the production task by utilizing the historical production element data and obtain first configuration data;
Acquiring current production element data;
And inputting the current production element data into the virtual model for simulation so as to correct the first configuration data by utilizing the current production element data to obtain second configuration data.
3. The method of claim 1, wherein the step of determining the position of the substrate comprises,
The step of generating a scheduling instruction based on the simulation result, and scheduling the equipment of the production shop according to the scheduling instruction, comprises the following steps:
acquiring historical production data;
generating a scheduling instruction according to the historical production data, the simulation result and the production data, and scheduling equipment of the production workshop according to the scheduling instruction.
4. The method of claim 1, wherein the step of determining the position of the substrate comprises,
The simulation is performed on a virtual model based on the production data, and a simulation result is obtained, including:
inputting the production data into the virtual model for simulation so as to obtain a fault prediction result and/or a productivity prediction result of the production workshop;
The generating a control instruction according to the simulation result to control equipment or environment of the production workshop comprises the following steps:
and generating a control instruction according to the fault prediction result and/or the productivity prediction result so as to perform fault monitoring or productivity monitoring on equipment in the production workshop.
5. A management terminal for a production plant, the management terminal comprising a processor and a memory coupled to the processor;
Wherein the memory is for storing program data and the processor is for executing the program data to implement the method of any of claims 1-4.
6. A computer readable storage medium for storing program data which, when executed by a processor, is adapted to carry out the method of any one of claims 1-4.
7. A control system for a production plant, the control system comprising:
the data acquisition device is arranged in the production workshop and is used for acquiring production data of the production workshop;
a management terminal connected to the data acquisition device, the management terminal being the management terminal according to claim 5.
8. The management and control system of claim 7, further comprising:
And the network equipment is connected with the data acquisition device and is used for acquiring the production data, transmitting and storing the production data.
9. The management and control system of claim 8, wherein,
The data acquisition device comprises at least one of an RFID device, a mold sensor and an equipment controller;
the RFID device is connected with the network equipment, is arranged at a preset station of the production workshop and is used for collecting personnel data of the production workshop;
The die sensor is connected with the network equipment and is used for collecting the operation data of the die;
The equipment controller is connected with the network equipment and is arranged on equipment of the production workshop and used for controlling the equipment and sending operation data of the equipment to the network equipment.
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